Plant Commissioning and Start-Up 2010

Conquering management and technical challenges of your plant start-up and commissioning
process by harnessing the key issues involved to ensure timely and cost efficient start-up

Prince Hotel and Residence “Efficiency is doing things right; effectiveness is

Kuala Lumpur, Malaysia doing the right things” Peter Drucker

1st & 2nd November 2010

Starting up safely and on time with a flawless commissioning sequence and proper
planning to accelerate your ROI

Your distinguished chairpersons: Featuring international commissioning and start-up experts:

Jeffrey Joyce Commissioning Manager
Phil Stoor Senior Control Electrical Project Manager
BHP Billiton Petroleum, Australia
ICON Engineering, UK
Philip GJ Stoor has 37 years of experience in control and Dr Martin Pitt MPhil, PhD, CChem, CEng, FIChemE, FRSC Co-ordinator of
instrumentation from a wide range of client and vendor Design Teaching
industries University of Sheffield, UK
Dr Himadri Banerji Former CEO
Abdelkader Houari Expansion and Start-Up Manager
Reliance Energy, India
Qatargas
Himadri Banerji has was the CEO and Senior Vice President of
Reliance Energy heading multibillion dollar infrastructure Hassan Fallatah Deputy Head HOFCC section (Monomer Department)
development multinational projects with operations in Oil and Petro Rabigh, Saudi Arabia
Gas, Energy, Steel, Aluminum, Real Estate, Highways, Airports
and Port Andrew Oosthuizen Pr. Eng Functional Manager Commissioning Engineering
Sasol Technology, South Africa

Fraser Brown Chief Operating Officer

Falcon Global (UK) Ltd – Zenator Systems
Featuring an optional post conference
course on 3rd November 2010: Wayne Harris Board of Director
World Safety Organisation, Qatar
Commissioning safety course
Facilitated by: Zia Naeem Siddiqui Project Manager
Robert Edward Lamey Regional Safety Specialist Engro Polymers and Chemicals, Pakistan
Chevron, Thailand
Robert is the Regional MOC Advisor, Safe Work Practices Advisor Fawaz Bitar VP Operations - Asia Pacific
and the global Contractor Health Environment and Safety BP Exploration and Production, Indonesia
Advisor. He is also one of only two certified high level Incident
Investigation (TapRooT) facilitators Arun C Senior Department Manager
TATA Steel, Thailand

Key benefits of attending:

Featuring case studies and expert • Redefining the responsibilities of various departments to ensure a flawless start-up
presentations: • Ensuring that safety measures are put in place to ensure zero LTIs during
Hitesh Shah Special Projects Advisor commissioning
Vinyl Chloride, Malaysia and start-up
• Benchmarking your commissioning practices against previous commissioning and
Noor Zulkifli Facilities Manager (Oil) start-up experiences
Petronas Carigali, Malaysia
• Acquiring risk management techniques for better prediction of what can go wrong
Mohammad Nasir Man Principal Engineer - Commissioning during the commissioning and start-up process and identify and plan effective mitigation
PETRONAS Group Technology Solutions, Malaysia measures
• Identifying and planning effective mitigation measures
Alex Tan Project Management Executive (Construction & • Accelerating the ROI of your plant through proper planning and management of
Commissioning) resources during the commissioning process
PETRONAS Group Technology Solutions, Malaysia
• Capturing the essence of commissioning and start-up in Greenfield and Brownfield
scenarios

*Early Bird & Group Discounts

Ask about our savings

conferences
Our Business Partners
Silver Sponsor

Business Development Sponsors

Media Partners

About the Silver Sponsor

Falcon Global’s flagship product Zenator Systems is the industry standard asset integrity
management system. A suite of 8 products, this completions management tool will deliver
a flawless transition from planning through construction into maintenance. Cutting edge
barcode ITR and ruggedized mobile device solutions will be demonstrated live at the
conference.

About the Business Development Sponsors

About the Media Partners
Since 1981 Plant and Works Engineering magazine (PWE) has had the privilege
to report on the many changes in the manufacturing and commercial sectors. The
magazine’s content focuses on just about every aspect of our readership’s professional Since its establishment in 1947, Hyundai E&C is renowned for its reputation as a symbolic
interests and responsibilities, reflecting the multitasking needs of today’s professionals. company representing the Korean construction industry. It has contributed to the
PWE’s editorial programme reflects the multitasking culture that now exists in the work development of Korea's economy playing a pivotal role in constructing domestic key
place, and also has a dedicated monthly maintenance feature – Maintenance Matters – infrastructure and raising the reputation of the Korean construction industry through the
looking at all aspects of plant maintenance, and problem solving case studies – the only performance of numerous overseas projects with advanced technology and challenging spirit.
magazine in its sector to give such detailed coverage every single month. Visit our website
at: www.pwemag.co.uk
Worldoils.com is new but fast growing web portal, provides almost all the information
needs of the oil and gas industry. Focused content in the portal, with the professional and
serious visitor and user in mind, is moving Worldoils towards the position where it plans
to be – the central place for all the world's oil and gas information. This is creating a solid
platform for the event organizers, equipment and service providers, consultants,
researchers and the training organizations to showcase their services. Worldoils is also
now developing into a oil, gas and biofuels research and consultancy house. Emerson Process Management is a leader in helping businesses automate their
production, processing and distribution in the chemical, oil and gas, refining, power, water &
Hydrocarbon Asia is the region's only hydrocarbon processing industry (HPI) magazine. wastewater treatment, mining & metals, marine & offshore, life sciences and other related
There is also PetroMin Pipeliner, Asia's first magazine covering pipelines & RAMS Asia industries. The company combines superior products and technology with industry-specific
(reliability, availability,maintainability &safety) Asia, the first publication in the area to cover engineering, consulting, project management and maintenance services. Its brands include
maintenance & safety. This, together with the PetroMin Hydrocarbon Asia Oil & Gas PlantWeb®, Fisher®, Micro Motion®, Rosemount®, Mobrey®, Bristol®, Roxar, Daniel®,
Annual Map & Directory (now into the 21st year), makes AP Energy Business Publications DeltaV™, Ovation®, AMS™ Suite, Machinery Health™ and CSI. For more details of our
Asia's most complete oil and gas publishers. Visit our website - www.safan.com - for the services, products and technology, please visit www.AP.EmersonProcess.com or call us at Tel:
full details (65) 6777 8211 for an appointment.

conferences
Day 1

Monday 1st November 2010

0800 Registration & morning coffee 1230 Networking luncheon

0900 Introduction and welcoming remarks from the chairperson Commissioning strategies
Phil Stoor Senior Control Electrical Project Manager
ICON Engineering, UK 1400 Session Five – Expert Presentation
Identifying the need for commissioning activities to start during
Commissioning management the FEED stage
• Defining the contract type and handover principles during the FEED phase
0915 Session One – Keynote Presentation • Determining who will be in-charge of the various stages of commissioning:
Accelerating start-up and commissioning process with effective Owner or contractor?
corrective strategies • Clearly defining the contractor scope even before the tendering process for ease
• Examining the key differences between commissioning and normal start-up of work
• Identifying the current commissioning problems experienced on international • Organising the commissioning project based on brownfield or greenfield projects
projects and anticipating the contingency plans for each project
• Utilising “commissioning governance” policy as a starting point Zia Naeem Siddiqui Project Manager
Engro Polymers and Chemicals, Pakistan
• Analysing the newest trends for effective commissioning process
Zia headed the recently concluded PVC Expansion & Back Integration Project, the
Hitesh Shah Special Projects Advisor
project comprised of capacity addition to their existing PVC plant, setting up of a
Vinyl Chloride, Malaysia
pre-owned EDC/VCM plant, construction of new chlor alkali plant, utilities plant
Hitesh has proven abilities in enhancing production process operations, optimising and a power plant
resources, productivity and process improvements and projects execution including
commissioning & start-ups 1445 Session Six – Case study
Sharpening your instrument commissioning process to ensure a
0945 Session Two – Expert Presentation smooth running plant after start-up
Predicting your project’s commissioning and start-up cost to • Establishing the key indices in planning instrument commissioning for a flawless
ensure your project is within budget start-up
• Analysing the commissioning and start-up cost estimation factors and looking at • Strategising to improve the instrument commissioning process by learning from
detailed budget considerations for the project best practices in instrument commissioning
• Calculating the forgotten start-up cost and identifying wastages in the system • Appraising the principles of an effective instrument commissioning process
• Minimising the start-up and commissioning cost for increased project ROI • Isolating the common challenges encountered during instrument commissioning
• Understanding empirical rules developed for estimating start up time and cost and strategies to overcome it
which provides sufficient accuracy for inclusion in the initial project budget Phil Stoor Senior Control Electrical Project Manager
Andrew Oosthuizen Pr. Eng Functional Manager Commissioning ICON Engineering, UK
Engineering Philip GJ Stoor has 37 years of experience in control and instrumentation from a
Sasol Technology, South Africa wide range of client and vendor industries

1030 Morning refreshments and networking break 1530 Afternoon refreshments and networking break

1100 Session Three – Case Study 1600 Session Seven – Case study
Isolating the keys to a smooth commissioning sequence that will Establishing an efficient spare parts plan for your commissioning
enable your organisation to have a flawless start-up process
• Exploring the critical success factors for commissioning and start-up of a project • Identifying spare parts and materials required to support commissioning activities
• Gaining from good know how of planning tools, controls and checklist to ensure • Selecting the best materials at the right price via detailed analysis of systematic
seamless commissioning procedures
• Recognising the steps in designing the roadmap for successful commissioning • Keeping in mind the specific plant design or plant modifications during selection
and start-up of materials for increased project quality
• Preparing and executing the commissioning and start-up and incorporating it • Employing the reorder point system and periodic reorder system in managing
with the operations implementation work process independent demand inventories
Arun C Senior Department Manager • Managing timelines to be synchronised with the commissioning process to
TATA Steel, Thailand ensure that commissioning supplies are adequate for the project
Alex Tan Project Management Executive (Construction & Commissioning)
PETRONAS Group Technology Solutions, Malaysia
1145 Session Four – Case Study
Alex has been involved in 7 commissioning projects in PETRONAS a majority of
Efficiently managing your commissioning and start-up to ensure
them being Greenfield project
proper coordination of tasks for a seamless start-up
• Reviewing your contractor, owner, engineering department and operations
1645 Session Eight – Case Study
department involvement and responsibilities in your commissioning plan
Incorporating world class HSE practices in your commissioning
• Developing and revising your preventive maintenance programmes and
and start-up plan
procedures with your vendors to ensure effective programme implementation
• Is world-class health and safety realistic in the present economic climate
• Implementation of preventive maintenance programme and procedures in your
plant: How to align it with your commissioning process • Picking up lessons learnt from case studies of HSE failure and future impacts to
your organisation
Abdelkader Houari Expansion and Start-Up Manager
Qatargas • Achieving a balance between cost and benefits of incorporating HSE in your
commissioning plan
Abdelkader has extensive experience of more than 29 years in hydrocarbon
processing with specialisation in Liquefied Natural Gas (LNG) and sulfur recovery • Tying in corporate governance and integrating stakeholder requirements to
process in the LNG industry enforce the intensity of HSE practices
Wayne Harris Board of Director
World Safety Organisation, Qatar
HSE Director, QPM
CEO, ISQEM
Wayne is a highly regarded international specialist in developing corporate risk
management systems, with over 27 years experience in health and safety within
high-risk environments
marcus evans would like to thank everyone who has helped with the research and
organisation of this event, particularly the speakers and their staff for their support and
commitment.
1730 Closing remarks from the chairperson and end of day one
 Register Now
Day 2 Contact Marketing at marcus evans
Tel: +603 2723 6757
Fax: +603 2723 6699
Tuesday 2nd November 2010 Email: [email protected]

0800 Registration & morning coffee 1230 Networking luncheon

0900 Welcoming remarks from the chairperson 1400 Session Five – Expert Presentation
Dr Himadri Banerji Former CEO Mitigating start-up problems and effectively troubleshooting it
Reliance Energy, India to prevent hiccups during operations
• Revisiting start-up problems and scrutinising the causes of outages throughout
Knowledge management for commissioning and the project
start-up • Locating the root of the problem from project inception to completion
• Strategising on how to minimise problems and consequences during
0915 Session One – Keynote Presentation commissioning and start-up
Accelerating start-up and initial operations with good knowledge Dr Martin Pitt MPhil, PhD, CChem, CEng, FIChemE, FRSC Co-
management, documentation and handovers ordinator of Design Teaching
• Start-up and initial operation: The link between timelines, consequences and the University of Sheffield, UK
roadmap to success Dr. Martin is the chief editor and main contributor to a very popular book
• Effective trouble shooting and problem correction during start-up “Instrumentation and Automation in Process Control” (M. J. Pitt & P. E. Preece,
• Strategies for taking the plant to full operations and maintaining forward 1990) and is currently working on a book on Commissioning
momentum
• Ensuring project quality through standardised data collection and storage plus 1445 Session Six – Expert Presentation
adequate documentation for quality audits every time Evaluating the benefits of a risk based commissioning and start-
Jeffrey Joyce Commissioning Manager up process
BHP Billiton Petroleum, Australia • Putting in place identification of risk specific to commissioning and start-up of a
Jeffrey has extensive experience on projects in the Russian Republic, the Far East, plant
Middle East, Singapore and China working on Refineries, Gas Plants, FPSO’s and • Choosing the right risk assessment techniques and parameters for your plant
Pharmaceutical projects in managerial and completions roles commissioning and start-up scenario
• Drawing up a competent risk management programme to ensure the safety of
0945 Session Two – Expert Presentation your commissioning site
Maximising Zenator for on time and safe start-up: Industry standard • Enforcing performance indicators to measure and manage risk
project completions and asset integrity management systems • Establishing multilevel HAZOP assessment to minimise the impact of risk
• Presenting Falcon Global and Zenator as a new way of working Dr Himadri Banerji Former CEO
• Surveying case studies of Zenator Power Users: Training the trainer, empowering Reliance Energy, India
the end user Himadri Banerji has was the CEO and Senior Vice President of Reliance Energy
• Learning from the live demo of Zenator Live online via Citrix heading multibillion dollar infrastructure development multinational projects with
• Previewing cutting edge commissioning solutions using ruggedized handheld operations in Oil and Gas, Energy, Steel, Aluminum, Real Estate, Highways,
devices: Live demo of Walk Down Capture Airports and Port
• Customising your reports via Reports Plus: Live demo of Reports Plus
• Documenting for the future: Paperless solutions for check sheets and ITRs 1530 Afternoon refreshments and networking break
Fraser Brown Chief Operating Officer
Falcon Global (UK) Ltd – Zenator Systems 1600 Session Seven – Case Study
Lessons learnt from the Tangguh LNG start-up:
1015 Morning refreshments and networking break • An overview of the project: geography, scale and complexity
• Identifying the organisational capability required for a safe and efficient start-up
1045 Session Three – Case Study
• Technical Lessons Learned from the project
Constructing a strong team and customising training of the
- Engineering and design
commissioning and start-up team to ensure success of your project
- Construction and commissioning
• Coming up with a sound commissioning team structure to ensure
commissioning success - Start-up and operations
• Mastering the management requirements timeline to ensure timely plant start-up • Achieving high reliability efficient operations post start-up
• Selecting the right staff for your team: Do they have what it takes to guarantee Fawaz Bitar VP Operations - Asia Pacific
success BP Exploration and Production, Indonesia
• The importance of well trained and knowledgeable start-up and commissioning Fawaz Bitar is responsible for BP's operations in the region and was responsible
team to ensure project success for the commissiong and start-up of the Tangguh LNG project in Indonesia
• Assessing the training needs of your team members and identifying the
essentials to a good training programme 1645 Session Eight – Case Study
• Effects of inexperienced team members on start-up and commissioning Flawless commissioning of the COGEN expansion project at the
Hassan Fallatah Deputy Head HOFCC section (Monomer Department) Melaka refinery
Petro Rabigh, Saudi Arabia • Reviewing the project planning process of the expansion project and isolating
Hassan was in charge of the pre-commissioning, commissioning and initial start- key milestones for a good start-up
up of the world’s largest High Olefin plant which was achieved in time with an • Studying the COGEN plant configuration for flawless commissioning process
outstanding remarkable safety record • Scrutinising the commissioning activities carried out in the plant and the pivotal
points for success
1130 Session Four – Panel Discussion Noor Zulkifli Facilities Manager (Oil)
Performing start-up operations on time and flawlessly Petronas Carigali, Malaysia
• Executing the initial start-up activities: Brownfield vs Greenfield Zulkifli has vast experience with job titles ranging from project manager to
• Discussing the secrets to maintaining a forward momentum commissioning manager in greenfield, brownfield and various refinery projects
• Expecting the expected and unexpected until the final plant acceptance stage projects
• Relooking your performance test run preparation and criteria
Moderator: 1730 Closing remarks from the chairperson and end of conference
Phil Stoor Senior Control Electrical Project Manager
ICON Engineering, UK

Panelists:
Dr Himadri Banerji Former CEO
Reliance Energy Professional In-House Courses
If you have a number of delegates with similar event needs, then you may wish to consider
Mohammad Nasir Man Principal Engineer – Commissioning
having a professional in-house course delivered locally on-site. Course can be tailored to
PETRONAS Group Technology Solutions
specific requirements.
For further details, please use the contact information given on the last page of this brochure.

marcus evans reserves the right to change the venue of, or speakers at the conference should circumstances require. © marcus evans
Optional 3rd day course on commissioning safety

Wednesday 3rd November 2010

Commissioning safety course

Your course facilitator:
A safe start-up of facilities should be the main goal of the commissioning phase, this one
Robert Edward Lamey Regional Safety Specialist
day course will go through all the important elements to ensure that your plant will start-
Chevron
up safely
Robert is the Regional MOC Advisor, Safe Work Practices Advisor and the global
Contractor Health Environment and Safety Advisor. He is also one of only two certified
Pre Start-Up Safety Review (PSSR) high level Incident Investigation (TapRooT) facilitators
Recognised for Health, Environment and Safety
Session One
Chevron operates its facilities in a way that protects the health and safety of its
Establishing the needs and benefits of performing PSSR in plant
employees, contractors and customers. Chevron’s workers demonstrate these principles
• Correlating PSSR to other process safety elements every day through:
• Looking at PSSR from a risk-based approach • Safety, health and environment awareness
• Determining the scope of a PSSR and other considerations such as process safety, • Pollution prevention
environmental, quality and personnel safety • Emergency preparedness and response
Chevron also is a founding member of East Asia Response Ltd., a regional emergency
Session Two
response center based in Singapore. The organisation is always ready to respond to
Comprehending the important elements of a PSSR environmental incidents by mobilising resources for the containment and removal of
• Reviewing the process of PSSR and understanding the risk-based approach to PSSR hazardous materials
• Identifying the importance of training in PSSR
• Scrutinising scheduling considerations when conducting a PSSR

Session Three Why you cannot miss this event

Reviewing the key regulatory issues affecting your PSSR
Commissioning of a new plant facility is a high risk. Engineers have to work under time
• Going through an overview of PSSR industry guidelines and regulations constraints and have to simultaneously execute many complex processes which could go
• Learning from best practices to carryout an effective PSSR for a safe start-up wrong. One of the biggest challenges is commissioning brownfield projects where a
• Grasping environmental, general safety, security and occupational health considerations new facility has to be integrated with existing facilities, with some facilities that are more
than 20 years old.
Session Four In order to achieve a safe and successful commissioning there has to be improved
Utilising a risk-based approach to PSSR project coordination and control on contractor and project management people and
• Using the right risk analysis techniques to select the level of detail for a PSSR also by the plant’s operations and control team. This conference will focus on the
• Drawing up a decision guideline for designing your PSSR important aspects of planning and the management of the commissioning process,
managing the interface between pre-commissioning, mechanical completion and
• Typical considerations for all PSSR
commissioning. All aspects of commissioning from handover to production and initial
start-up of the facilities will be discussed. Do not miss the opportunity to attend this
Hands on exercise: unique one of a kind international event.
• Going through an example of risk-based questionnaire
• Take home best practices from examples of using a risk-based approach to PSSR design

Session Five
The PSSR work process Testimonials from past events:
• Taking into consideration the PSSR sub-elements in designing and implementing a PSSR “It is the perfect topic!”
program Project Manager
ADMA-OPCO
• Getting ready to perform a PSSR
• Strategies in implementing good follow up on PSSR action items “I have explored a new aspect for effective commissioning and start-up at this
• Approving the PSSR report conference”
Commissioning Engineer
• Methodologies for compiling and using a PSSR checklist Descon Engineering
Session Six “First of its kind conference that was really excellent. I’m waiting in anticipation for
Encouraging continuous improvement in your plant even beyond start-up future events on the same topic. Networking opportunities were great”
Senior Commissioning Engineer
• Diagnosing your PSSR system issues
Sasol Technology
• Keys to training your staff and communicating action plan effectively for continuous
improvement “The commissioning and start-up conference was really a profitable experience that
will certainly help Vale to get a smooth and fast commissioning in Onca Pula Plant”
• Examining excesses as well as deficiencies in your system
Commissioning Manager
• Distinguishing the need to refine, improve, upgrade, or redesign your PDDR system Vale Brazil
• Grasping case studies on PSSR performance and efficiency metrics
“This conference has a good mix of experience in one room”
• Calculating the audit frequency and qualification considerations for PSSR auditors
Start-up team leader
• Addressing audit results and effectively communicating results for enhanced reliability PETRORabigh KSA
“marcus evans has brought me a new learning curve”
Start-up Manager
Sabic
“A good job done with ample opportunities for networking and knowledge sharing. I
Who should attend look forward to more from marcus evans”
Directors, Vice Presidents, General Managers, Heads of Departments, Senior Process Engineer
Managers, Managers, Supervisors and Engineers from the following job areas: Petronas
• Commissioning • Start-Up
“With this event, I can benchmark my commissioning and start-up processes”
• Operations • Process Engineering CIGI Philippines
• Projects • Expansion
• Revamp • Plant
• Factory • Maintenance
• Engineering • Production Engineering
• Technical Services • Process Experts
Programme schedule
• Facilities Management • Contractors 0830 Morning coffee & registration
• Equipment Specialist • Construction 0900 Course begins
• Maintenance Planner • Manufacturing 1030 Morning refreshments and networking break
1100 Course commences
From the following industries
1245 Networking luncheon
• Oil and Gas • Petrochemical Industry
1400 Course re-commences
• Steel • Mining
1530 Afternoon refreshments and networking break
• Power & Utilities • Manufacturing Industry; Chemicals and
Hazardous Goods / Hazardous Operational 1600 Course re-commences
Processes / Heavy Manufacturing 1730 Course concludes